India’s tyre recycling sector, long plagued by fragmented operations and lax compliance, is undergoing a critical overhaul. With Gujarat’s recent approval for continuous pyrolysis plants, the industry is moving decisively towards cleaner, scalable and regulation-driven solutions. This shift signals more than a technological upgrade and it’s a rebuke of outdated batch systems and a call for formalisation, traceability and environmental accountability. As global demand for sustainable materials rises, India’s pivot positions it as a potential leader in circular economy practices. In conversation with TRRAI President Chetan Joshi, we explore how this development could redefine the future of tyre waste management at home and abroad.

India’s tyre recycling sector is on the cusp of a transformational shift with the Gujarat Pollution Control Board (GPCB) approving the establishment of continuous pyrolysis plants in the state. The move marks a significant departure from traditional batch-based tyre processing systems, promising to boost efficiency, environmental compliance and resource recovery at an industrial scale.

“This shift is nothing short of revolutionary,” said President of the Tyre and Rubber Recyclers Association of India (TRRAI) Chetan Joshi. “We’re moving from outdated, fragmented batch operations to streamlined, automated continuous pyrolysis systems. This is going to uplift the entire industry, from cleaner emissions to higher resource recovery, better traceability and serious investor interest. It sets a new national standard and will accelerate formalisation, industrial-scale operations and a far more sustainable approach across India.”

The approval has been met with optimism by recyclers and environmental advocates alike as it signifies a structural change in how end-of-life tyres will be handled in India, which is home to more than 1.8 million tonnes of tyre waste annually.

The Gujarat model mandates stringent adherence to environmental standards, particularly concerning air quality and emissions. Continuous pyrolysis plants approved under the new framework are required to incorporate top-tier pollution control mechanisms.

“We see compliance not as an obligation but as a core design principle. Our plants are being built with advanced air pollution control devices (APCDs), real-time emissions monitoring and automation that ensures consistent performance. We’re aligning with both GPCB and CPCB regulations through pro-active design, third-party audits and integrating global best practices. It’s not just about meeting today’s standards but staying ahead of tomorrow’s,” said Joshi.

The approach reflects a broader shift in the recycling sector, where regulatory compliance is no longer viewed as a hurdle but as a strategic advantage and market differentiator.

Industrial scale

Under the new directive, each continuous pyrolysis facility must operate at a minimum capacity of 60 tonnes per day (TPD). This scale reflects the government’s push to industrialise tyre recycling and eliminate inefficient, informal practices.

“Scaling to 60 TPD is a serious industrial commitment and it means heavy investment in automation, utilities, safety systems and logistics. But it’s also the only way forward. India generates over 1.8 million tonnes of end-of-life tyres annually. This scale allows us to handle the problem responsibly while creating traceable and economically viable recycling ecosystems,” Joshi said.

With India’s growing automotive base, the urgency to develop sustainable, high-capacity recycling infrastructure has never been higher.

One of the key advantages of continuous pyrolysis lies in its outputs that include valuable petrochemical byproducts like pyrolysis oil, sustainable fuels and recovered carbon black (rCB). These materials are increasingly in demand across a range of industries, from rubber manufacturing to renewable energy.

“These by-products are entering a new phase of global relevance. Recovered carbon black is being adopted in rubber, plastics and even pigments. Pyro oil, when upgraded, is a viable alternative fuel. We’re actively engaging with global buyers and certifiers to standardise and integrate these outputs into international supply chains. The world is ready for sustainable alternatives and it’s up to us to deliver with consistency and quality,” averred Joshi.

India’s entry into this global supply chain positions it not just as a recycler of waste but as a producer of sustainable industrial materials.

Circular economy

TRRAI views this milestone as more than an environmental success. It’s a step towards realising India’s vision of a circular economy, where tyre waste is fully reintegrated into the production cycle.

“We aim to be more than recyclers. We want to be circular economy enablers. That means building systems where tyre waste is traceable from collection to output, where value is recovered and re-injected into the economy. We’re developing collection infrastructure, digital traceability and offtake agreements with industries globally. This is not just about waste; it’s about resource optimisation and environmental stewardship,” Joshi explained.

Such a shift could significantly reduce the country’s carbon footprint while fostering job creation and industrial growth.

Despite the enthusiasm, industry leaders acknowledge that challenges remain, particularly in terms of adoption among legacy operators and infrastructure gaps.

“The biggest challenge is inertia as many operators are still working in the unorganised sector with outdated setups. Then there’s infrastructure as a hurdle as tyre collection networks are underdeveloped in many parts of India. To overcome this, we’re advocating policy changes, investing in reverse logistics and training the workforce. Regulatory clarity and enforcement will be key and we’re working closely with industry associations and government bodies to drive this,” said Joshi.

Stakeholders believe that education, investment and enforcement will be pivotal to ensuring widespread transition to continuous pyrolysis systems.

Global trends

Globally, countries like those in Europe and North America have already adopted advanced tyre recycling technologies. But Joshi believes India has a unique opportunity to leapfrog older systems and build world-class facilities from scratch.

“Europe and North America have a head start, especially in policy frameworks and end-use applications. But India’s opportunity lies in scale and adaptability. We can leapfrog legacy systems and build efficient, tech-driven plants from the ground up. If we get the ecosystem right – collection, compliance and capital – we can set new benchmarks, not just catch up. India could become a global hub for tyre recycling technology,” he said.

The industry’s fast pace of development combined with India’s manufacturing and engineering capabilities could make the country a case study in sustainable industrial transformation.

Innovations in emission reduction

In line with global best practices, TRRAI and its partners are integrating innovations to ensure safety and minimal environmental impact.

“We’re integrating closed-loop systems, AI-driven control logic and multi-stage gas cleaning technology. Real-time emissions data will be available both internally and to regulators. Safety protocols are built into every operational layer, from material feeding to shutdown procedures. We’ve also prioritised workforce training and regular third-party safety audits. The goal is to operate with zero compromise on health or the environment,” Joshi explained.

Such innovations are crucial not only to maintaining regulatory compliance but also to building public and investor confidence.

The entry of advanced technologies is expected to catalyse foreign investment and technical collaboration.

“Our approach is partnership-driven. We’re already working with European and Australian technology providers and are in discussions with institutional investors. We see India as a platform for co-creation, where global IP meets local scale and agility. Through industry associations like TRRAI, we’re building collaborative networks to ensure knowledge sharing, investment facilitation and joint innovation,” Joshi noted.

This strategy could help India become a global innovation hub for recycling technologies applicable across other emerging markets.

The vision

Looking to the long term, the industry’s goals extend far beyond domestic waste management. TRRAI envisions exporting its model to developing nations facing similar challenges.

“Our vision is bold but simple. It is to create a fully circular, scalable and replicable tyre recycling ecosystem. India should not only solve its own tyre waste crisis but become a global model for how emerging markets can tackle resource recovery. We see this model being exported to Southeast Asia, Africa and Latin America. With continuous pyrolysis, India can move from reactive recycling to proactive resource management on a global stage,” Joshi concluded.

As Gujarat lights the way with its approval of continuous pyrolysis plants, India’s tyre recycling sector is poised to become a beacon of innovation and sustainability – one that could shape the future of global recycling practices. n

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Kuraray Co., Ltd. marked its 100th anniversary on 24 June 2026, with a commemorative ceremony at the Tokyo International Forum. The company live-streamed the event to its domestic and overseas locations, enabling employees worldwide to join the celebration simultaneously and strengthening the Group's collective spirit.

The speciality chemical company expressed deep appreciation to its stakeholders and predecessors for their enduring support throughout the century. Leaders also reaffirmed the organisation's determination to pursue new challenges collaboratively as it embarks on its next hundred years.

Hitoshi Kawahara, President, Kuraray Co., Ltd.

President Hitoshi Kawahara called for uniting values across diverse countries, regions, languages and cultures during this pivotal moment. He advocated for realising ‘One Kuraray’ by actively connecting people, technologies and knowledge beyond conventional organisational and business boundaries to co-create fresh value.

Kuraray originated in 1926 in Kurashiki, Okayama Prefecture, with the commercial production of synthetic rayon. Over the past century, the company built its reputation on distinctive technologies, including PVA fiber, PVOH resin, CLARINO man-made leather and EVAL EVOH resin, guided by its mission to achieve what no other company can for people and the planet. Today, Kuraray operates across 32 countries and regions. The company now views its centennial as a launching point for tackling social challenges through innovation and for unlocking new possibilities in the years ahead.

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Cabot Corporation has once again achieved the top-tier platinum designation from EcoVadis, maintaining this elite status for six consecutive years. This accomplishment secures the company’s place among the global elite, as only one percent of all businesses scrutinised by the rating agency receive this highest mark. The outcome reflects the firm's sustained emphasis on driving tangible environmental and social advancements while upholding rigorous disclosure standards across its operational network.

The assessment framework employed by EcoVadis examines more than 150,000 entities worldwide, spanning numerous sectors and geographies, with evaluations rooted in established sustainability benchmarks. Cabot registered its most significant annual performance jump this cycle, with a five-point increase in its cumulative score, driven largely by enhanced results in the ethical conduct segment. Additionally, the company retained its exceptional standing in both environmental stewardship and workforce rights, securing the maximum possible recognition in those two critical areas.

With EcoVadis consistently tightening its evaluation parameters to mirror emerging global norms, Cabot has responded by intensifying its own internal sustainability measures. The organisation has concentrated on elevating operational effectiveness and data visibility, ensuring its practices remain responsive to the increasingly stringent expectations of stakeholders and rating bodies alike.

Underpinning this trajectory is a deeply ingrained organisational culture focused on iterative refinement and long-term value creation. By persistently elevating its sustainability agenda, Cabot reinforces its reputation as a proactive industry participant, dedicated to aligning corporate performance with broader societal and environmental objectives.

Jennifer Chittick, Senior Vice President, Safety, Health and Environment (SH&E) and Government Affairs; Chief Sustainability Officer, said, “We are encouraged by this year’s EcoVadis results, which reflect meaningful progress across our sustainability programme and our largest year-over-year score increase to date. These results demonstrate how greater transparency, stronger cross-functional collaboration and disciplined execution are helping us strengthen how we operate while advancing progress toward our 2030 sustainability goals.”

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Nokian Tyres has secured a position among TIME Magazine’s World’s Most Sustainable Companies for 2026, claiming the 100th spot on a prestigious roster of 750 global enterprises. The annual compilation, produced in partnership with the research firm Statista, recognises organisations demonstrating exceptional environmental and social performance after a comprehensive evaluation of thousands of candidates worldwide.

The selection process weighed verified sustainability credentials, including active participation in the UN Global Compact and Science Based Targets initiative-approved emission reduction goals. Assessment also incorporated third-party ratings from entities like CDP and MSCI, alongside rigorous scrutiny of each company’s transparent operations, ethical governance and overall commitment to environmental stewardship and social responsibility, ultimately distinguishing Nokian Tyres for its holistic approach to corporate accountability.

Paolo Pompei, President and CEO, Nokian Tyres, said, “This is a great acknowledgment of our long-term sustainability work and motivates us to keep improving. We want to enable drivers to make more sustainable tyre choices without compromising on performance. Renewable and recycled materials and lower rolling resistance help cut tyre lifecycle emissions, while rigorously tested tyres improve grip and safety, especially in demanding weather conditions. Proactive sustainability measures also benefit our customers: responsible sourcing reduces risks, and innovative, high-performing tyres with lower environmental footprint make it possible for our customers to offer higher-value solutions to their own clients.”

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Beratex, part of the Bernauer Group alongside Texpak, is positioning itself as a specialist partner to global tyre manufacturers at a time when efficiency demands, sustainability pressures and the technical requirements of electric mobility are reshaping the industry. In a sector often described as mature, the company argues that meaningful gains are still being unlocked – not through disruption but through materials innovation and process optimisation that deliver measurable improvements on the factory floor.

“Beratex and Texpak are both part of the Bernauer Group, which positions itself as a system supplier of specialised auxiliary and raw materials for the tyre and rubber industries. Beratex & Texpak sees itself as a trusted specialist partner to the global tyre industry, with a strong focus on high-performance product solutions. Our products help tyre manufacturers maintain stable, efficient and high-quality production processes across both PCR and TBR applications,” says Hanspeter Bernauer, Owner and CEO. “At the same time, building on our experience since 1972, we continue to expand our footprint in the tyre and rubber sector with complementary products such as low-melting EVA materials for mixing process and embossed PE films for single-use applications, which we distribute through our subsidiary Texpak.”

A key differentiator for Beratex is its vertically integrated production model, spanning from HDPE film supplied by its subsidiary Kunststoffwerk Lahr to in-house yarn production, weaving, heat-setting, hot-calandering, finishing and confectioning, allowing the company to manage the full value chain internally. In addition, its own hydropower generation plays an important role in ensuring supply reliability, efficiency and sustainability.

INCREMENTAL INNOVATION IN A MATURE INDUSTRY

Despite tyre manufacturing’s maturity, Bernauer sees ample scope for innovation – though largely incremental. “Even in a mature industry like tyre manufacturing, there is still considerable room for innovation. In our view, some of the most meaningful progress comes from better materials, more efficient processes and solutions that help customers reduce waste without compromising performance,” he says.

“Innovation does not always have to be disruptive. In many cases, the biggest improvements come from practical developments that make production more stable, cleaner and easier to automate. That is exactly where close cooperation between suppliers and manufacturers can create real value,” he adds.

FACTORY-FLOOR IMPACT AND CONSISTENCY

The operational impact of Bernauer Group’s solutions is most visible in production environments. Liner materials are engineered to stabilise the handling of uncured rubber and reduce variability.

“The most tangible benefits are seen directly on the production floor. Our liner solutions help improve handling reliability, reduce contamination risks and support a smoother, more consistent manufacturing process. As a result, customers benefit from fewer interruptions, lower material waste and more stable output,” Bernauer says.

Texpak’s EVA low-melting bags and films complement this by offering consistent processing behaviour, a defined melting point, consistent thickness, a reliable quality standard and integration into mixing processes.

“For tyre manufacturers, that means better process efficiency, improved product quality and more effective use of materials. In high-volume production, even small improvements in these areas can have a significant operational impact,” Bernauer says.

Consistency remains central to the value proposition. Bernauer notes that Beratex liners are designed to bring consistency and process reliability to high-volume tyre production, with PE and textile liners offering uniform gauges, controlled surface properties and reliable release performance, enabling uncured rubber components to be handled without deformation, contamination or unnecessary variability.

By reducing sticking, tearing and uneven release, these solutions support stable cycle times, smoother automation and lower rejection rates. “Another important advantage is the durability of our liners. Their long service life helps maintain stable conditions over extended production runs, reduces replacement frequency and contributes to overall efficiency on the factory floor,” he adds.

PRODUCTIVITY AND TOTAL VALUE

The company links these performance improvements directly to productivity metrics. “Our solutions can have a very direct impact on factory-floor productivity. When liners perform reliably, manufacturers experience fewer stoppages due to sticking, tearing, misfeeds or contamination. That helps keep line speeds stable and supports better throughput,” Bernauer says.

He explains that by adapting liner solutions to the specific requirements of a process, the company helps customers improve handling, reduce waste  and strengthen production control, contributing, in practice, to better overall equipment effectiveness and a more predictable manufacturing environment.

This underpins a broader emphasis on total value rather than initial price, reflecting the economics of high-volume manufacturing.

EVOLVING EXPECTATIONS: COST, PERFORMANCE AND SUSTAINABILITY

Supplier expectations have shifted materially over the past decade. “Customer expectations have changed significantly over the last 10 years. In the past, the focus was often on price and basic functionality. Today, tyre manufacturers expect much more: reliable performance, process consistency, compatibility with automation and clear added value,” Bernauer says.

Sustainability is now central, with Bernauer noting that customers increasingly look for solutions that support material reduction, recyclability and a lower environmental impact while also expecting closer technical cooperation and more customised support – factors that have made supplier relationships significantly more strategic than before.

“Today, it is clearly a combination of all three,” he says, referring to cost, performance and sustainability. “Cost pressure remains important, but manufacturers also understand that performance and process reliability directly affect efficiency, quality and total production cost. The most attractive solutions are therefore the ones that combine cost efficiency, performance and sustainability rather than treating them as trade-offs.”

REGIONAL SHIFTS AND GLOBAL SUPPLY CHAINS

The tyre industry’s geographic footprint continues to evolve. “Yes, we are seeing clear regional shifts in both demand and manufacturing. Capacity continues to move towards Asia and other cost-competitive regions, driven by local market growth, export opportunities and broader supply chain diversification,” Bernauer says.

At the same time, new regions are emerging. “We are also seeing increasing activity in regions that previously played a smaller role in the global landscape, including parts of Africa,” adds Bernauer.

This creates a dual requirement for suppliers: global consistency and local flexibility.

SUSTAINABILITY IN SOURCING AND PRODUCTION

Sustainability considerations are reshaping procurement decisions, with Bernauer noting that the biggest change is that sourcing decisions are no longer driven by price alone, as tyre manufacturers increasingly assess recyclability, material efficiency, carbon footprint and the overall environmental profile of their suppliers. There is also a growing focus on reducing waste through downgauging and the use of reusable materials.

“Beratex is very well positioned in this respect. We generate 100 percent of our electricity from renewable sources through our own hydropower plants, and we can fully recycle all our production waste and reprocess it into new products,” he says.

EV-DRIVEN REQUIREMENTS

Electric vehicles are tightening manufacturing tolerances. According to Bernauer, the rise of electric vehicles is raising the bar for tyre manufacturers, with EV tyres typically requiring tighter dimensional precision, higher load-bearing performance and very consistent production conditions.

“For us, that means developing liner solutions with even greater surface consistency, controlled release behaviour and clean processing performance,” he says.

DIFFERENTIATION THROUGH DURABILITY

Durability and long-term performance are central to the company’s positioning. “What sets Beratex apart is that we combine proven product performance with a strong understanding of manufacturing realities. Our liner solutions are designed to deliver consistent quality, reliable release performance and exceptional durability, with customer references showing Beratex liners in use for over 15 years when properly handled,” Bernauer says.

Bernauer notes that with more than 135 million square metres of liner solutions supplied, the company’s track record demonstrates both long-term product performance and customer trust, adding that the focus remains on total value rather than just initial price.

REDUCING DEFECTS AND WASTE

At a functional level, the materials are designed to minimise defects. Bernauer explains that, in simple terms, the company’s materials help tyre manufacturers handle uncured rubber components cleanly and consistently. When release performance is stable and the liner behaves predictably, there is less risk of sticking, tearing or surface damage.

“Texpak EVA materials help reduce defects and waste in tyre production by offering consistent melting behaviour, uniform thickness and reliable quality,” Bernauer adds.

CHALLENGES AND OUTLOOK

The operating environment remains pressured. “One of the main challenges is the overall cost pressure in a highly competitive market,” Bernauer says, citing raw material volatility and supply chain disruptions. “Another challenge is meeting rising sustainability expectations while still delivering the functional performance customers require,” he adds.

Looking ahead, he identifies two key opportunity areas. “The first is advanced and more sustainable material solutions,” he says, pointing to the demand for recyclable and environmentally responsible products.

“The second is the ongoing shift towards higher-performance tyres, including EV-related applications, which require greater precision, cleanliness and process stability,” he adds.

For Bernauer Group, the approach remains consistent: deepen process integration, refine materials and deliver incremental improvements that scale across global tyre manufacturing.

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